U.S. patent application number 12/531420 was filed with the patent office on 2010-04-22 for process for synthesis of clay particles.
This patent application is currently assigned to SHAYONANO SINGAPORE PTE LTD. Invention is credited to Mahesh Dahyabhai Patel.
Application Number | 20100098614 12/531420 |
Document ID | / |
Family ID | 39766618 |
Filed Date | 2010-04-22 |
United States Patent
Application |
20100098614 |
Kind Code |
A1 |
Patel; Mahesh Dahyabhai |
April 22, 2010 |
PROCESS FOR SYNTHESIS OF CLAY PARTICLES
Abstract
A process for synthesizing clay particles comprising the step of
heating a reactant solution mixture of metal salt and a metal
silicate using a radiation source under conditions to form said
synthetic clay particles.
Inventors: |
Patel; Mahesh Dahyabhai;
(Singapore, SG) |
Correspondence
Address: |
OSHA LIANG L.L.P.
TWO HOUSTON CENTER, 909 FANNIN, SUITE 3500
HOUSTON
TX
77010
US
|
Assignee: |
SHAYONANO SINGAPORE PTE LTD
Singapore
SG
|
Family ID: |
39766618 |
Appl. No.: |
12/531420 |
Filed: |
March 14, 2008 |
PCT Filed: |
March 14, 2008 |
PCT NO: |
PCT/SG2008/000080 |
371 Date: |
September 15, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60895317 |
Mar 16, 2007 |
|
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|
Current U.S.
Class: |
423/328.1 ;
423/327.1; 423/331; 423/465 |
Current CPC
Class: |
C01B 33/40 20130101 |
Class at
Publication: |
423/328.1 ;
423/465; 423/327.1; 423/331 |
International
Class: |
C01B 33/40 20060101
C01B033/40; C01F 7/50 20060101 C01F007/50; C01B 33/26 20060101
C01B033/26; C01B 33/24 20060101 C01B033/24 |
Claims
1. A process for synthesizing clay particles comprising the step of
heating a reactant solution mixture of metal salt and a metal
silicate using a radiation source under conditions to form said
clay particles.
2. A process according to claim 1 comprising the step of selecting
said metal silicate from the group consisting of lithium silicate,
sodium silicate, potassium silicate, beryllium silicate, magnesium
silicate and calcium silicate.
3. A process according to claim 1 comprising using a molar excess
of metal silicate relative to said metal salt said reactant
solution mixture.
4. A process according to claim 1 wherein said radiation source is
a microwave radiation source.
5. A process according to claim 4, comprising the step of applying
said microwaves at a power in the range of 30 W to 180 KW or 30 W
to 1200 W.
6. A process according to claim 4, comprising the step of applying
said microwaves with a frequency is in the range of 0.3 GHz to 300
GHz.
7. A process according to claim 4, comprising the step of applying
said microwaves for a period of time in the range of 20 minutes to
2 hours.
8. A process according to claim 1 wherein said heating is
undertaken under a substantially alkaline pH condition.
9. (canceled)
10. (canceled)
11. A process according to claim 8 comprising the step of adding a
metal hydroxide solution to said reactant mixture to obtain said
alkaline pH condition.
12. A process according to claim 1 wherein said metal of said metal
salt is a multi-valent metal salt solution.
13. A process according to claim 1 wherein said metal of said metal
salt is selected from the group consisting of alkali metals,
alkaline earth metals, a metals of group IIIA, VIIB and VIII of the
Periodic Table of Elements.
14. A process according to claim 13 wherein said metal of said
metal salt is selected from the group consisting of sodium,
potassium, lithium, magnesium, calcium, aluminium, iron, and
manganese.
15. A process according to claim 13 wherein said anion of said
metal salt is a halide.
16. (canceled)
17. A process according to claim 1 wherein said metal salt and said
source of silicates are selected to synthesize the clay particles
selected from the group consisting of chryolite, chlinochlore,
kaolinite, nontronite, paragonite, phlogopite, pyrophyllite,
smectite, talc, vermiculaite and mixtures thereof.
18. A process according to claim 17 wherein said smectite clay is
selected from the group consisting of bentonite, beidellite,
hectorite, montmorillonite, saponite, stevensite, and mixtures
thereof.
19. A process according to claim 1 comprising the step of removing
said clay particles from said reactant solution.
20. A process according to claims 19 comprising the step of drying
said removed clay particles to substantially remove extraneous
water therefrom.
21. A process according to claim 19 wherein said drying step is
carried out at a temperature of about 250 degree C.
22. A process according to claim 19 wherein said drying step is
carried out for about 8 hours.
23. A process according to claim 1, wherein the particle size of
said clay particles is in the nano-meter range to the micrometer
range.
24. (canceled)
25. (canceled)
Description
TECHNICAL FIELD
[0001] The present invention generally relates to a process for
synthesizing clay particles.
BACKGROUND
[0002] Clays generally refer to a highly variable group of natural
materials that are soft, earthy, extremely fine grained, usually
plastic when moist and consisting of one or a mixture of various
clay minerals and impurities. Alkaline metals such as sodium,
lithium and potassium and alkaline earth metals such as magnesium,
calcium and barium are often present in the molecular structure of
clays and have a significant effect in their physical and chemical
properties.
[0003] Clays play a very important role in many industries. Their
use depends upon their physical and chemical properties. Some of
these uses include manufacturing of face bricks, chimney flue
linings, sewer pipes, stoneware and earthenware pottery, fire
bricks, production of aluminum, kaolin fibres, porcelain, as a
component in portland cement, synthetic zeolites, wall and floor
tiles, rubber, as a filler for paper, paint, adhesives, sealants,
extender, whitening, caulking, reinforcing agent and production of
lightweight aggregate as a substitute for gravel in concrete
products
[0004] However, large quantities of natural clays are not readily
available and are usually mixed with impurities. The removal of
these impurities from the clays can be extremely difficult. It is
therefore desirable to be able to synthesize synthetic clay
particles that are in a substantially pure state and which have
desirable rheological properties similar to, or better than,
naturally occurring clays.
[0005] One of the known processes for synthesizing synthetic clay
particles involves a straightforward co-precipitation step with an
alkali and fluoride ion and subsequent hydrothermal treatment which
involves convectional heating with agitation under reflux at
atmospheric pressure and in some cases with high temperature and
high pressure. However, the hydrothermal treatment step usually
requires a time period of at least 10 to 20 hours. This is because
the process time for conventional heating to take place is limited
by the rate of heat flow into the body of the material from the
surface as determined by its mass in addition to its specific heat,
thermal conductivity, density and viscosity. Convectional heating
therefore suffers from the disadvantage of being a slow
process.
[0006] Furthermore, the high pressures results in the need for
specialized equipments such as pressure vessels, which increase the
capital and operating costs associated with industrial scale plants
to synthesize the clay particles.
[0007] Another disadvantage of convectional heating is non-uniform
because the surfaces, edges and corners of the particles being
heated are much hotter than the inside of the material.
[0008] There is a need to provide a process for synthesizing clay
particles that overcomes, or at least ameliorates, one or more of
the disadvantages described above.
SUMMARY
[0009] According to a first aspect, there is provided, a process
for synthesizing clay particles comprising the step of heating a
reactant solution mixture of metal salt and a metal silicate using
a radiation source under conditions to form said synthetic clay
particles.
[0010] Advantageously, in one embodiment, the heating step is
undertaken without convectional heating.
[0011] Advantageously, in one embodiment, the heating step is
undertaken without conductive heating.
[0012] Advantageously, in one embodiment, the heating step is
undertaken using a microwave heating source.
[0013] Advantageously, the use of a radiation source provides an
energy efficient synthesis process for synthesizing clay particles
as lesser time may be required for co-precipitation of the
synthetic clay particles from the solution mixture.
[0014] Advantageously, the use of a radiation source also allows
better control of the size and shape and uniformity in composition
of the particles being synthesized.
[0015] According to a second aspect of the invention, there is
provided a clay particle made in a process according to the first
aspect.
DEFINITIONS
[0016] The following words and terms used herein shall have the
meaning indicated:
[0017] The term "synthetic clay" is to be interpreted broadly to
include materials related in structure to layered clays and porous
fibrous clays such as synthetic hectorite (lithium magnesium sodium
silicate). It will be appreciated that within the scope of the
invention the following classes of clays have application alone or
in combination and in mixed layer clays: kaolinites, serpentines,
pyrophyllites, talc, micas and brittle micas, chlorites, smectites
and vermiculites, palygorskites and sepiolites. Other
phyllosilicates (clay minerals) which may be employed in the
tablets according to the invention are allophane and imogolite. The
following references describe the characterisation of clays of the
above types: Chemistry of Clay and Clay Minerals. Edited by A. C.
D. Newman. Mineralogical Society Monograph No. 6, 1987, Chapter 1;
S. N. Bailey; Summary of recommendations of AIPEA Nomenclature
Committee, Clay Minerals 15, 85-93; and A Handbook of Determinative
Methods in Mineralogy, 1987, Chapter 1 by P. L. Hall.
[0018] The term "radiation source" is to be interpreted broadly to
include any electromagnetic waves that are capable of heating an
aqueous solution.
[0019] The term "metal silicate" is to be interpreted broadly to
include any compounds having a metal cation forming a bond with a
silicate anion.
[0020] The term "silicate" is to be interpreted broadly to include
any anion in which one or more central silicon atoms are surrounded
by electronegative ligands such as oxygen.
[0021] The word "substantially" does not exclude "completely" e.g.
a composition which is "substantially free" from Y may be
completely free from Y. Where . necessary, the word "substantially"
may be omitted from the definition of the invention.
[0022] Unless specified otherwise, the terms "comprising" and
"comprise", and grammatical variants thereof, are intended to
represent "open" or "inclusive" language such that they include
recited elements but also permit inclusion of additional, unrecited
elements.
[0023] As used herein, the term "about", in the context of
concentrations of components of the formulations, typically means
+/-5% of the stated value, more typically +/-4% of the stated
value, more typically +/-3% of the stated value, more typically,
+/-2% of the stated value, even more typically +/-1% of the stated
value, and even more typically +/-0.5% of the stated value.
[0024] Throughout this disclosure, certain embodiments may be
disclosed in a range format. It should be understood that the
description in range format is merely for convenience and brevity
and should not be construed as an inflexible limitation on the
scope of the disclosed ranges. Accordingly, the description of a
range should be considered to have specifically disclosed all the
possible sub-ranges as well as individual numerical values within
that range. For example, description of a range such as from 1 to 6
should be considered to have specifically disclosed sub-ranges such
as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6,
from 3 to 6 etc., as well as individual numbers within that range,
for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the
breadth of the range.
DISCLOSURE OF OPTIONAL EMBODIMENTS
[0025] Exemplary, non-limiting embodiments of a process for
synthesizing synthetic clay particles will now be disclosed.
[0026] The metal silicate may be any alkali metal silicate or
alkaline earth metal silicate or blend thereof. Exemplary metal
silicates include lithium silicate, sodium silicate, potassium
silicate, beryllium silicate, magnesium silicate and calcium
silicate.
[0027] In one embodiment, the reactant solution mixture comprises a
molar excess of the metal silicate relative to the metal salt.
[0028] Advantageously, heating using a radiation source allows
heating of a material at substantially the same rate throughout its
volume, that is, it enables volumetric heating. Heat energy from
the radiation source is transferred through the heated material
electro-magnetically. Consequently, the rate of heating is not
limited by the rate of heat transfer through a material as during
convectional or conductive heating, and the uniformity of heat
distribution is greatly improved. Heating times may be reduced to
less than one percent of that required using convectional or
conductive heating.
[0029] Exemplary radiation sources include radio waves, microwaves,
infrared, ultraviolet, X-rays and gamma rays. In one embodiment,
the radiation source is a microwave radiation source. The two main
mechanisms of microwave heating are dipolar polarization and
conduction mechanism. Dipolar polarization is a process by which
heat is generated in polar molecules. When an electromagnetic field
is applied, the oscillating nature of the electromagnetic field
results in the movement of the polar molecules as they try to align
in phase with the field. However, the inter-molecular forces
experienced by the polar molecules effectively prevent such
alignment, resulting in the random movement of the polar molecules
and generating heat. Conduction mechanisms result in the generation
of heat due to resistance to an electric current. The oscillating
nature of the electromagnetic field causes oscillation of the
electrons or ions in a conductor such that an electric current is
generated. The internal resistance faced by the electric current
results in the generation of heat. Accordingly, the microwaves may
be used to produce high temperatures uniformly inside a material as
compared to conventional heating means which may result in heating
only the external surfaces of a material.
[0030] The microwaves may be applied at a power in the range
selected from the group consisting of about 30 W to about 180 KW,
about 30 W to about 150 KW, about 30 W to about 120 KW, about 30 W
to about 100 KW, about 30 W to about 50 KW, about 30 W to about 25
KW, about 30 W to about 15 KW, about 30 W to about 10 KW, about 30
W to about 5 KW, about 30 W to about 2 KW, about 30 W to about 1200
W, about 50 W to about 1200 W, about 100 W to about 1200 W, about
200 W to about 1200 W, about 300 W to about 1200 W, about 400 W to
about 1200 W, about 500 W to about 1200 W, about 600 W to about
1200 W, about 700 W to about 1200 W, about 800 W to about 1200 W,
about 900 W to about 1200 W, about 1000 W to about 1200 W, about 30
W to about 1100 W, about 30 W to about 100 W, about 30 W to about
80 W, about 30 W to about 60 W, about 30 W to about 40 W, about 40
W to about 120 W, about 60 W to about 120 W, about 80 W to about
120 W, about 100 W to about 120 W, about 70 W to about 100 W and
about 50 W to about 70 W.
[0031] Typical frequencies of microwaves may be in the range of
about 300 MHz to about 300 GHz. This range may be divided into the
ultra-high frequency range of 0.3 to 3 GHz, the super high
frequency range of 3 to 30 GHz and the extremely high frequency
range of 30 to 300 GHz. Common sources of microwaves are microwave
ovens that emit microwave radiation at a frequency of about 0.915,
2.45, or 5.8 GHz. The microwaves may be applied with a frequency in
the range selected from the group consisting of about 0.3 GHz to
about 300 GHz, about 0.3 GHz to about 200 GHz, about 0.3 GHz to
about 100 GHz, about 0.3 GHz to about 50 GHz, about 0.3 GHz to
about 10 GHz, about 0.3 GHz to about 5.8 GHz, about 0.3 GHz to
about 2.45 GHz, about 0.3 GHz to about 0.915 GHz and about 0.3 GHz
to about 0.9 GHz.
[0032] In one embodiment, the microwave heating is conducted for a
period of time in the range of about 10 minutes to 2 hours.
[0033] The heating process may be undertaken under substantially
alkaline pH conditions. In one embodiment, the pH is in the range
of at least 8.5. Advantageously, the pH is in the range of 9 to 10.
This is to provide an optimum environment for the co-precipiation
of the clay particles from the reactant mixture. In one embodiment,
a metal hydroxide solution is added to the reactant solution
mixture to obtain said alkaline pH condition.
[0034] The metal of the metal salt may be a multi-valent metal.
This metal may be selected from the group consisting of alkali
metals, alkaline earth metals, a metals of group IIIA, VIIA and
VIII of the Periodic Table of Elements. Exemplary metal include
sodium, potassium, lithium, magnesium, calcium, aluminium, iron,
and manganese.
[0035] The anion of the metal salt may be a halide. Exemplary anion
include chloride and fluoride.
[0036] The metal salt and metal silicates may be selected to
synthesize the clay particles selected from the group consisting of
chryolite, chlinochlore, kaolinite, nontronite, paragonite,
phlogopite, pyrophyllite, smectite, talc, vermiculaite and mixtures
thereof. Exemplary smectite clay include bentonite, beidellite,
hectorite, montmorillonite, saponite, stevensite, and mixtures
thereof.
[0037] The process may further comprise a step for removing of the
clay particles from the reactant solution mixture. The removed clay
particles may then be dried to substantially remove extraneous
water therefrom. In one embodiment, the drying is carried out at a
temperature of about 250 degree C. for about 8 hours.
[0038] The particle size of the clay particles may be in the
nano-meter range to the micrometer range. In one embodiment, the
mean size of the clay particles ranges from about 20 nm to 120
nm.
BRIEF DESCRIPTION OF DRAWINGS
[0039] The accompanying drawings illustrate a disclosed embodiment
and serve to explain the principles of the disclosed embodiment. It
is to be understood, however, that the drawings are designed for
purposes of illustration only, and not as a definition of the
limits of the invention.
[0040] FIG. 1 is a schematic diagram of process for mixing of the
reactants to form a reactant solution mixture and a microwave oven
for irradiating microwaves for co-precipitation of synthetic clay
particles from the reactant solution mixture therein.
[0041] FIG. 2 is a process flow chart for synthesizing clay
particles.
[0042] FIG. 3 is an X-ray diffraction pattern of the experimental
sample obtained in Example 2 in comparison with Laponite.RTM.
(Southern Clay Particles, Inc., Tex.).
[0043] FIG. 4 is an X-ray diffraction pattern of the experimental
sample obtained in Example 3 in comparison with Laponite.RTM.
(Southern Clay Particles, Inc., Tex.).
[0044] FIG. 5 is an X-ray diffraction pattern of the experimental
sample obtained in Example 4 in comparison with Laponite.RTM.
(Southern Clay Particles, Inc., Tex.).
[0045] FIG. 6 is an X-ray diffraction pattern of the experimental
sample obtained in Example 5 in comparison with Laponite.RTM.
(Southern Clay Particles, Inc., Tex.).
DETAILED DISCLOSURE OF EMBODIMENTS
[0046] Referring to FIG. 1 there are shown two tanks (10,20) with
mixers (12,22) respectively disposed therein for mixing the
solutions respectively contained therein. Tank contains a metal
salt solution which is mixed homogeneously therein by means of the
mixer 12. Simultaneously, a metal silicate solution is
homogeneously mixed in tank 20 by means of the mixer 22. The metal
salt solution stream 14 and metal silicate solution stream 24
respectively obtained from the two tanks (10,20) are pumped into
the reaction tank 30 using the respective pumps (16,26) as
shown.
[0047] The reaction tank 30 comprises a mixer 32 to enable
homogeneous mixing of the reactants obtained from the metal salt
solution stream 14 and the metal silicate solution stream 24. The
reaction tank 30 also comprises an alkaline feed stream 34 which
allows the addition of an alkali such as sodium hydroxide to the
solution contained therein, thereby raising the pH to alkaline
conditions.
[0048] The reactant solution mixture hence obtained from the
reaction tank 30 is pumped via a pump 56 through a stream 54 into a
tank 52. The tank 52 is made of a material that is able to
withstand microwave radiation without undergoing any physical or
chemical changes. The tank 52 is contained within a microwave oven
40 used as a radiation source for radiating microwaves to heat up
the reactant solution mixture contained in the tank 52.
[0049] The microwave oven 40 comprises a wall 42 that is
impermeable to the radiation or microwaves that are produced
therein. The tank 52 containing the reactant solution mixture
therein is placed in the controlled environment 44 of the microwave
oven 40, and exposed to the microwave radiation generated therein.
The microwave radiation in the controlled environment 44 is a
microwave field emitted at a frequency of about 0.3 GHz to 300 GHz
with a power of 30 W to 180 kW.
[0050] The energy released by the microwave field initiates and
promotes a chemical reaction between the reactants in the reactant
solution mixture contained in the tank 52. This results in the
co-precipitation of the synthetic clay particles from the reactant
solution mixture. The mixture of synthetic clay particles and
solvent hence obtained therein then passes through the product
mixture stream 36 into a filter tank 38.
[0051] The product mixture is washed and filtered in the filter
tank 38 to obtain a filtrate 46, that is, the solvent, and a
residue 48, that is, the synthetic clay particles.
[0052] FIG. 2 shows a process flow diagram for the synthesis
synthetic clay particles. The synthesis process generally comprises
the step of mixing 50 the reactants (metal salt and, metal silicate
solutions) to form a reactant solution mixture under the condition
of an alkaline pH. The reactant solution mixture is then placed in
a microwave oven to allow for co-precipitating 60 of the synthetic
clay particles from the reactant solution mixture. Washing and
filtering 70 steps further process a product mixture hence obtained
from the co-precipitation 60 step. The filtered product is then put
for drying 80 at 250 degree C. for 8 hours. Dried synthetic clay
particles in a substantially pure state are then obtained.
EXAMPLES
[0053] A non-limiting example of the invention will be further
described, which should not be construed as in any way limiting the
scope of the invention.
Example 1
[0054] A first tank was loaded with 69 g of magnesium chloride (99%
purity), 2.12 g of lithium chloride (99% purity) and 500 ml of
water. The 88 gm Solution of Sodium Silicate (29 g Si.sub.2O and
8.9 g Na.sub.2O per 100 gm) is diluted in 500 ml of water. The
reaction solutions are respectively homogenously mixed in the first
and second tanks before being transferred into a reaction tank over
a period of 30 minutes with constant stirring. 0.11 M sodium
hydroxide is then added drop-wise to raise the pH of the reactant
solution mixture in the reaction tank 9.5. The reactant solution
mixture in the reaction tank is agitated for 30 minutes. The
reaction tank is contained within a microwave oven with a power up
to 1000 W, emitting microwave radiation at a frequency of 2.45 GHz
for 30 minutes. The product mixture is washed with water and
filtered; The filtered product is dried at 250.degree. C. for 8
hour. Analysis of the precipitate indicated that the precipitate
particles were synthetic clay and had an average particle size of
about 30 nm. This indicates that microwave heating without any
convectional heating is a viable means by which to synthesize clay
particles.
Example 2
[0055] A first tank was loaded with 49.94 g of magnesium chloride
(99% purity), 4.45 g of lithium chloride (99% purity) and 900 ml of
water. The 166 gm Solution of Sodium Silicate (29 g Si.sub.2O and
8.9 g Na.sub.2O per 100 gm) is diluted in 900 ml of water. The
reaction solutions are respectively homogenously mixed in the first
and second tanks before being transferred into a reaction tank over
a period of 30 minutes with constant stirring. 0.11 M sodium
hydroxide is then added drop-wise to raise the pH of the reactant
solution mixture in the reaction tank to 9.5. The reaction tank is
contained within a microwave oven with a power up to 5000 W
operating with a frequency of 2.45 GHz. The reaction tank is then
subjected to microwave radiation at a power of 1100 W for 10
minutes followed by at a power of 330 W for 50 minutes. The product
mixture is washed with water and filtered. The filtered product is
dried at 250.degree. C. for 8 hours.
[0056] FIG. 3 shows the X-ray diffraction pattern of the
experimental product (labeled as "sample7") obtained in accordance
with the experimental protocol described above in comparison with a
commercially available product, Laponite.RTM. (Southern Clay
Particles, Inc., Tex.) (labeled as "standard1"). As shown in FIG.
3, the X-ray diffraction pattern of the experimental product
obtained is similar to that of Laponite.RTM.. Accordingly, it has
been shown that the three dimensional atomic structure of the
experimental product (synthetic clay particles) obtained in
accordance with the disclosure herein is comparable to commercially
available products.
Example 3
[0057] The experiment is repeated in accordance with the steps in
Example 2 up to the step of adjustment of the pH of the reactant
solution mixture in the reaction tank to 9.5. In this Example, the
reaction tank is then subjected to microwave radiation at a power
of 3800 W for 10 minutes followed by at a power of 1100 W for 30
minutes. The product mixture is washed with water and filtered. The
filtered product is dried at 250.degree. C. for 8 hours.
[0058] FIG. 4 shows the X-ray diffraction pattern of the
experimental product (labeled as "Wim-T30") obtained in accordance
with the experimental protocol described above in comparison with a
commercially available product, Laponite.RTM. (Southern Clay
Particles, Inc., Tex.) (labeled as "standard1"). As shown in FIG.
4, the X-ray diffraction pattern of the experimental product
obtained is similar to that of Laponite.RTM.. Accordingly, it has
been shown that the three dimensional atomic structure of the
experimental product (synthetic clay particles) obtained in
accordance with the disclosure herein is comparable to commercially
available products.
Example 4
[0059] The experiment is repeated in accordance with the steps in
Example 2 up to the step of adjustment of the pH of the reactant
solution mixture in the reaction tank to 9.5. In this Example, the
reaction tank is then subjected to microwave radiation at a power
of 1100 W for 10 minutes followed by at a power of 800 W for 4
minutes. The product mixture is washed with water and filtered. The
filtered product is dried at 250.degree. C. for 8 hours.
[0060] FIG. 5 shows the X-ray diffraction pattern of the
experimental product (labeled as "wk1_1T10wk0_8T30") obtained in
accordance with the experimental protocol described above in
comparison with a commercially available product, Laponite.RTM.
(Southern Clay Particles, Inc., Tex.) (labeled as "standard1"). As
shown in FIG. 5, the X-ray diffraction pattern of the experimental
product obtained is similar to that of Laponite.RTM.. Accordingly,
it has been shown that the three dimensional atomic structure of
the experimental product (synthetic clay particles) obtained in
accordance with the disclosure herein is comparable to commercially
available products.
Example 5
[0061] The experiment is repeated in accordance with the steps in
Example 2 up to the step of adjustment of the pH of the reactant
solution mixture in the reaction tank to 9.5. In this Example, the
reaction tank is then subjected to microwave radiation at a power
of 3800 W for 10 minutes followed by at a power of 1100 W for 16
minutes. The product mixture is washed with water and filtered. The
filtered product is dried at 250.degree. C. for 8 hours.
[0062] FIG. 6 shows the X-ray diffraction pattern of the
experimental product (labeled as "wk3800T10wk1100T16") obtained in
accordance with the experimental protocol described above in
comparison with a commercially available product, Laponite.RTM.
(Southern Clay Particles, Inc., Tex.) (labeled. as "standard1"). As
shown in FIG. 6, the X-ray diffraction pattern of the experimental
product obtained is similar to that of Laponite.RTM.. Accordingly,
it has been shown that the three dimensional atomic structure of
the experimental product (synthetic clay particles) obtained in
accordance with the disclosure herein is comparable to commercially
available products.
APPLICATIONS
[0063] It will be appreciated that the disclosed process is a
continuous process.
[0064] It will be appreciated that the disclosed process does not
involve the use of high pressure or high temperature. This
effectively reduces capital and operating costs.
[0065] It will be appreciated that the disclosed process produces
synthetic clay particles of uniform size, shape and
composition.
[0066] It will be appreciated that the disclosed process requires
less time for production of the synthetic clay particles. This is
possible due to the use of a radiation source instead of
conventional heating methods for the co-precipitation of the
synthetic clay particles.
[0067] It will be appreciated that the disclosed process produces
synthetic clay particles that are in a substantially pure state.
Furthermore, the disclosed process does not require complicated
purifying steps to obtain pure synthetic clay particles.
[0068] It will be appreciated that the disclosed process produces
synthetic clay particles that have several commercial applications.
The synthetic clay particles can be used as or in the manufacturing
of a rheology modifier in aqueous solution, a film forming agent, a
catalyst or base for catalyst, nanocomposites or energy storage
nanocomposites, optic electronics, photovoltaic and organic light
emitting diodes, and sensors such as humidity sensors or
biosensors.
[0069] It will be apparent that various other modifications and
adaptations of the invention will be apparent to the person skilled
in the art after reading the foregoing disclosure without departing
from the spirit and scope of the invention and it is intended that
all such modifications and adaptations come within the scope of the
appended claims.
* * * * *